Method of manufacturing a plastic tank

Abstract

A process for manufacturing a plastic tank for a motor vehicle. The process includes inserting at least one stiffening profile into a shell mould having walls. The at least one stiffening profile is configured to minimise undesirable deformation of the plastic tank. The process also includes applying a negative pressure to simultaneously maintain a position of each stiffening profile in the shell mould, form a tank wall by facilitating flow of plastic material onto the walls of the shell mould, and form a form-fitting connection between the tank wall and each stiffening profile by facilitating flow of the plastic material around the stiffening profile.

What is claimed is: 
     
         1 . A process for manufacturing a plastic tank for a motor vehicle, the process comprising:
 inserting at least one stiffening profile into a shell mould having walls, the at least one stiffening profile configured to minimise undesirable deformation of the plastic tank; and   applying a negative pressure to simultaneously: maintain a position of each stiffening profile in the shell mould, form a tank wall by facilitating flow of plastic material onto the walls of the shell mould, and form a form-fitting connection between the tank wall and each stiffening profile by facilitating flow of the plastic material around the stiffening profile.   
     
     
         2 . The process of  claim 1 , wherein the stiffening profile is composed of a fibre-reinforced plastic. 
     
     
         3 . The process of  claim 1 , wherein inserting the at least one stiffening profile comprises inserting the at least one stiffening profile into a corresponding recess of the shell mould. 
     
     
         4 . The process of  claim 3 , wherein applying negative pressure comprises maintaining the position of each stiffening profile in the corresponding recess of the shell mould. 
     
     
         5 . The process of  claim 1 , further comprising, before inserting the at least one stiffening profile, producing the at least one stiffening profile by extrusion. 
     
     
         6 . The process of  claim 1 , further comprising, before inserting the at least one stiffening profile, producing the at least one stiffening profile by injection moulding. 
     
     
         7 . The process of  claim 1 , further comprising, before inserting the at least one stiffening profile, producing the at least one stiffening profile to have a plurality of openings such that, during formation of the tank wall, the plastic material flows through the openings to form the forming-fitting connection. 
     
     
         8 . The process of  claim 1 , further comprising, before inserting the at least one stiffening profile, producing the at least one stiffening profile to have a longitudinal recess at least at one end. 
     
     
         9 . The process of  claim 1 , further comprising, before inserting the at least one stiffening profile, bending the at least one stiffening profile into a shape adapted to the tank wall. 
     
     
         10 . The process of  claim 1 , further comprising, after applying the negative pressure, strengthening the forming-fitting connection by reducing the size of the tank wall via conduction of a cooling process. 
     
     
         11 . A process for manufacturing a tank for a motor vehicle, the process comprising:
 inserting at least one stiffening profile, composed of a fibre-reinforced plastic, into a corresponding recess of a plastic shell mould having walls, the at least one stiffening profile configured to minimise undesirable deformation of the tank; and   applying a negative pressure to simultaneously: maintain a position of each stiffening profile in the corresponding recess of the shell mould, form a tank wall by facilitating flow of plastic material onto the walls of the shell mould, and form a form-fitting connection between the tank wall and each stiffening profile by facilitating flow of the plastic material around the stiffening profile.   
     
     
         12 . The process of  claim 11 , further comprising, before inserting the at least one stiffening profile, producing the at least one stiffening profile by extrusion. 
     
     
         13 . The process of  claim 11 , further comprising, before inserting the at least one stiffening profile, producing the at least one stiffening profile by injection moulding. 
     
     
         14 . The process of  claim 11 , further comprising, before inserting the at least one stiffening profile, producing the at least one stiffening profile to have a plurality of openings such that, during formation of the tank wall, the plastic material flows through the openings to form the forming-fitting connection. 
     
     
         15 . The process of  claim 11 , further comprising, before inserting the at least one stiffening profile, producing the at least one stiffening profile to have a longitudinal recess at least at one end. 
     
     
         16 . The process of  claim 11 , further comprising, before inserting the at least one stiffening profile, bending the at least one stiffening profile into a shape adapted to the tank wall. 
     
     
         17 . The process of  claim 11 , further comprising, after applying the negative pressure, strengthening the forming-fitting connection by reducing the size of the tank wall via conduction of a cooling process. 
     
     
         18 . A process for manufacturing a tank for a motor vehicle, the process comprising:
 inserting at least one stiffening profile into a shell mould having walls; and   applying a negative pressure to simultaneously: maintain a position of each stiffening profile in the shell mould, form a tank wall by facilitating flow of material onto the walls of the shell mould, and form a form-fitting connection between the tank wall and each stiffening profile by facilitating flow of the material around the stiffening profile.   
     
     
         19 . The process of  claim 18 , further comprising, before inserting the at least one stiffening profile, producing the at least one stiffening profile to have a plurality of openings such that, during formation of the tank wall, the plastic material flows through the openings to form the forming-fitting connection. 
     
     
         20 . The process of  claim 18 , further comprising, before inserting the at least one stiffening profile, producing the at least one stiffening profile to have a longitudinal recess at least at one end.